Part 1

CYLINDER BLOCK ASSY
OVERHAUL
1. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
2. REMOVE WATER SEAL PLATE
3. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.
4. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.
5. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG
a. Using a socket hexagon wrench 10, remove the screw plug.





6. INSPECT CONNECTING ROD THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.
Standard thrust clearance: 0.15 to 0.30 mm (0.0059 to 0.0118 inch)
Maximum thrust clearance: 0.35 mm (0.0138 inch)
7. INSPECT CONNECTING ROD OIL CLEARANCE
a. Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
b. Remove the 2 connecting rod cap bolts.
c. Clean the crank pin, the bearing and the connecting rod.
d. Check the crank pin and bearing for pitting and scratches.





e. Lay a strip of plastigage across the crank pin.





f. Check that the protrusion of the connecting rod cap is facing the correct direction.
g. Apply a light coat of engine oil on the threads of the connecting rod cap bolts.





h. Tighten the bolts in several steps by the specified torque
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





i. Mark the front side of each connecting cap bolt with paint.
j. Retighten the cap bolts by 90° as shown in the illustration.

NOTICE: Do not turn the crankshaft.

k. Remove the 2 bolts, the connecting rod cap and the lower bearing.





1. Measure the plastigage at its widest point.
Standard oil clearance: 0.038 to 0.066 mm (0.0015 to 0.0026 inch)
Maximum oil clearance: 0.08 mm t0.0031 inch)

NOTICE: Completely remove the plastigage.





If replacing the bearing, replace it with one having the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.





HINT: Standard bearing center wall thickness





8. REMOVE PISTON SUB-ASSY W/CONNECTING ROD
a. Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push out the piston and the connecting rod assembly from the top of the cylinder block.

HINT:
^ Keep the bearings, the connecting rod and the cap together.
^ Arrange the piston and the connecting rod assemblies in correct order so they can be returned to the original locations when reassembling

9. REMOVE CONNECTING ROD BEARING





10. REMOVE PISTON RING SET
a. Using a piston ring expander, remove the 2 compression rings.
b. Remove the 2 side rails and oil ring by hand.





11. REMOVE PISTON PIN HOLE SNAP RING
a. Using a small screwdriver, pry out the 2 snap rings.
12. REMOVE W/PIN PISTON SUB-ASSY





a. Gradually heat the piston to approximately 80°C (176°F).





b. Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and remove the connecting rod.

HINT:
^ The piston and pin are a matched set.
^ Store the pistons, the pins, the rings, the connecting rods and the bearings in correct order so that they can be returned to the original locations when re-assembling.





13. INSPECT CRANKSHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0094 inch)
Maximum thrust clearance: 0.30 mm (0.0118 inch)
If the thrust clearance is greater than maximum, replace the thrust washers as a set. Check the crankshaft for wear, repair or replace if necessary.

HINT: Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 inch)

14. REMOVE CRANKSHAFT





a. Using several steps, loosen and remove the 8 main bearing cap bolts and seal washers uniformly in the sequence shown in the illustration.





b. Using several steps, loosen and remove the 16 main bearing cap bolts uniformly in the sequence shown in the illustration.








c. Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and the lower bearings.

NOTICE:
^ Carefully pry out the main bearing cap by alternating lifting a little at a time on each end the cap.
^ Be careful not to damage the joint surface of the cylinder block and the main bearing cap.

15. REMOVE CRANKSHAFT THRUST WASHER SET
16. REMOVE CRANKSHAFT BEARING





17. INSPECT CYLINDER BLOCK FOR FLATNESS
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage
Maximum warpage: 0.05 mm (0.0020 inch)
If warpage is greater than maximum, replace the cylinder block





18. INSPECT CYLINDER BORE
a. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.
Standard diameter: 92.000 to 92.012 mm (3.6220 to 3.6225 inch)
Maximum diameter: 92.080 mm (3.6252 inch)
If the diameter is greater than maximum, replace the cylinder block.





19. INSPECT W/PIN PISTON SUB-ASSY
a. Using a micrometer, measure a diameter of the piston. When you measure the diameter, attach the micrometer to a location where 13.0 mm (0.512 inch) above from the piston bottom and meets at the right angles to the piston pin hole.
Piston diameter: 91.953 to 91.967 mm (3.6202 to 3.6207 inch)
20. INSPECT PISTON OIL CLEARANCE
a. Subtract the piston diameter measurement from the cylinder bore diameter measurement.
Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 inch)
Maximum oil clearance: 0.13 mm (0.0051 inch)
If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block.
21. INSPECT CONNECTING ROD SUB-ASSY
a. Using a rod aligner and feeler gauge, check the connecting rod alignment.





1. Check for misalignment.
Maximum misalignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If misalignment is greater than maximum, replace the connecting rod assembly.





2. Check for twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If twist is greater than maximum, replace the connecting rod assembly.
22. INSPECT PISTON PIN OIL CLEARANCE





a. Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 inch)





b. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 inch)
c. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)
Maximum oil clearance: 0.05 mm (0.0020 inch)
If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and the piston pin together.





23. REMOVE CONNECTING ROD SMALL END BUSH
a. Using SST and a press, press out the bushing.
SST 09222-30010
24. INSTALL CONNECTING ROD SMALL END BUSH





a. Align the oil holes of a new bushing and the connecting rod.





b. Using SST and a press, press in the bushing.
SST 09222-30010





c. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin.
Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 inch)





HINT: Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.





25. INSPECT RING GROOVE CLEARANCE
a. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Ring groove clearance:
No.1 0.03 to 0.08 mm (0.0012 to 0.0031 inch)
No.2 0.02 to 0.06 mm (0.0008 to 0.0024 inch)
Oil 0.03 to 0.11 mm (0.0012 to 0.0043 inch)